Modeling of cutting forces in curvilinear peripheral milling process

Due to the increasing esthetic requirements and complex functional specifications of machined components, peripheral milling of curved geometries is becoming increasingly important in the aerospace, automotive, and the injection molds industries. However, one of the major difficulties encountered by manufacturers is that peripheral milling of the curved surfaces which is characterized by significant amount of engagement variation along the tool path causing a sudden change in cutting forces and consequently a deterioration of the surface roughness of the machined parts and lowers productivity. The present paper presents a two-dimensional machining model allowing the simulation of cutting forces including the cutting process damping in curvilinear peripheral milling. In the study, we attempt to analyze the effect of various milling parameters such as cutting speed, feed rate, axial and radial depth of cut, tool diameter, and tool helix angle on cutting forces generated by the peripheral milling of a curved surface profile. The cutting forces obtained through simulation model are compared with experimental results.